Chapter 1 Introduction to DeGarmo’s Materials and Processes in Manufacturing

1.1 Materials，Manufacturing，and the Standard of Living

1.2 Manufacturing and Production Systems

Case Study Famous Manufacturing Engineers

Chapter 2 Properties of Materials

2.1 Introduction

2.2 Static Properties

2.3 Dynamic Properties

2.4 Temperature Effects（Both High and Low）

2.5 Machinability Formability，and Weldability

2.6 Fracture Toughness and the Fracture Mechanics Approach

2.7 Physical Properties

2.8 Testing Standards and Concerns

Case Study Separation of Mixed Materials

Chapter 3 Nature of Metals and Alloys

3.1 Structure-Property-Processing-Performance Relationships

3.2 The Structure of Atoms

3.3 Atomic Bonding

3.4 Secondary Bonds

3.5 Atom Arrangements in Materials

3.6 Crystal Structures of Metals

3.7 Development of a Grain Structure

3.8 Elastic Deformation

3.9 Plastic Deformation

3.10 Dislocation Theory of Slippage

3.11 Strain Hardening or Work Hardening

3.12 Plastic Deformation in Polycrystalline Metals

3.13 Grain Shape and Anisotropic Properties

3.14 Fracture of Metals

3.15 Cold Working，Recrystallization，and Hot Working

3.16 Grain Growth

3.17 Alloys and Alloy Types

3.18 Atomic Structure and Electrical Properties

Chapter 4 Equilibrium Phase Diagrams and the Iron-Carbon System

4.1 Introduction

4.2 Phases

4.3 Equilibrium Phase Diagrams

4.4 Iron-Carbon Equilibrium Diagram

4.5 Steels and the Simplified Iron-Carbon Diagram

4.6 Cast Irons

Case Study The Blacksmith Anvils

Chapter 5 Heat Treatment

5.1 Introduction

5.2 Processing Heat Treatments

5.3 Heat Treatments Used to Increase Strength

5.4 Strengthening Heat Treatments for Nonferrous Metals

5.5 Strengthening Heat Treatments for Steel

5.6 Surface Hardening of Steel

5.7 Furnaces

5.8 Heat Treatment and Energy

Case Study A Carpenter’s Claw Hammer

Chapter 6 Ferrous Metals and Alloys

6.1 Introduction to History-Dependent Materials

6.2 Ferrous Metals

6.3 Iron

6.4 Steel

6.5 Stainless Steels

6.6 Tool Steels

6.7 Alloy Cast Steels and Irons

Case Study Interior Tub of a Top-Loading Washing Machine

Chapter 7 Nonferrous Metals and Alloys

7.1 Introduction

7.2 Copper and Copper Alloys

7.3 Aluminum and Aluminum Alloys

7.4 Magnesium and Magnesium Alloys

7.5 Zinc-Based Alloys

7.6 Titanium and Titanium Alloys

7.7 Nickel-Based Alloys

7.8 Superalloys and Other Metals Designed for High-Temperature Service

7.9 Lead and Tin，and Their Alloys

7.10 Some Lesser Known Metals and Alloys

7.11 Metallic Glasses

7.12 Graphite

Case Study Nonsparking Wrench

Chapter 8 Nonmetallic Materials：Plastics，Elastomers，Ceramics，and Composites

8.1 Introduction

8.2 Plastics

8.3 Elastomers

8.4 Ceramics

8.5 Composite Materials

Case Study Two-Wheel Dolly Handles

Chapter 9 Material Selection

9.1 Introduction

9.2 Material Selection and Manufacturing Processes

9.3 The Design Process

9.4 Procedures for Material Selection

9.5 Additional Factors to Consider

9.6 Consideration of the Manufacturing Process

9.7 Ultimate Objective

9.8 Materials Substitution

9.9 Effect of Product Liability on Materials Selection

9.10 Aids to Material Selection

Case Study Material Selection

Chapter 10 Measurement and Inspection and Testing

10.1 Introduction

10.2 Standards of Measurement

10.3 Allowance and Tolerance

10.4 Inspection Methods for Measurement

10.5 Measuring Instruments

10.6 Vision Systems for Measurement

10.7 Coordinate Measuring Machines

10.8 Angle-Measuring Instruments

10.9 Gages for Attributes Measuring

10.10 Testing

10.11 Visual Inspection

10.12 Liquid Penetrant Inspection

10.13 Magnetic Particle Inspection

10.14 Ultrasonic Inspection

10.15 Radiography

10.16 Eddy-Current Testing

10.17 Acoustic Emission Monitoring

10.18 Other Methods of Nondestructive Testing and Inspection

10.19 Dormant versus Critical Flaws

Case Study Measuring An Angle

Chapter 11 Fundamentals of Casting

11.1 Introduction to Materials Processing

11.2 Introduction to Casting

11.3 Casting Terminology

11.4 The Solidification Process

11.5 Patterns

11.6 Design Considerations in Castings

11.7 The Casting Industry

Case Study The Cast Oil-Field Fitting

Chapter 12 Expendable-Mold Casting Processes

12.1 Introduction

12.2 Sand Casting

12.3 Cores and Core Making

12.4 Other Expendable-Mold Processes with Multiple-Use Patterns

12.5 Expendable-Mold Processes Using Single-Use Patterns

12.6 Shakeout，Cleaning，and Finishing

12.7 Summary

Case Study Movable and Fixed Jaw Pieces for a Heavy-Duty Bench Vise

Chapter 13 Multiple-Use-Mold Casting Processes

13.1 Introduction

13.2 Permanent-Mold Casting

13.3 Die Casting

13.4 Squeeze Casting and Semisolid Casting

13.5 Centrifugal Casting

13.6 Continuous Casting

13.7 Melting

13.8 Pouring Practice

13.9 Cleaning，Finishing，and Heat Treating of Castings

13.10 Automation in Foundry Operations

13.11 Process Selection

Case Study Baseplate for a Household Steam Iron

Chapter 14 Fabrication of Plastics，Ceramics，and Composites

14.1 Introduction

14.2 Fabrication of Plastics

14.3 Processing of Rubber and Elastomers

14.4 Processing of Ceramics

14.5 Fabrication of Composite Materials

Case Study Fabrication of Lavatory Wash Basins

Chapter 15 Fundamentals of Metal Forming

15.1 Introduction

15.2 Forming Processes：Independent Variables

15.3 Dependent Variables

15.4 Independent-Dependent Relationships

15.5 Process Modeling

15.6 General Parameters

15.7 Friction and Lubrication under Metalworking Conditions

15.8 Temperature Concerns

Case Study Repairs to a Damaged Propeller

Chapter 16 Bulk Forming Processes

16.1 Introduction

16.2 Classification of Deformation Processes

16.3 Bulk Deformation Processes

16.4 Rolling

16.5 Forging

16.6 Extrusion

16.7 Wire，Rod，and Tube Drawing

16.8 Cold Forming，Cold Forging，and Impact Extrusion

16.9 Piercing

16.10 Other Squeezing Processes

16.11 Surface Improvement by Deformation Processing

Case Study Handle and Body of a Large Ratchet Wrench

Chapter 17 Sheet-Forming Processes

17.1 Introduction

17.2 Shearing Operations

17.3 Bending

17.4 Drawing and Stretching Processes

17.5 Alternative Methods of Producing Sheet-Type Products

17.6 Pipe Welding

17.7 Presses

Case Study Fabrication of a One-Piece Brass Flashlight Case

Chapter 18 Powder Metallurgy

18.1 Introduction

18.2 The Basic Process

18.3 Powder Manufacture

18.4 Rapidly Solidified Powder（Microcrystalline and Amorphous）

18.5 Powder Testing and Evaluation

18.6 Powder Mixing and Blending

18.7 Compacting

18.8 Sintering

18.9 Hot-Isostatic Pressing

18.10 Other Techniques to Produce High-Density P/M Products

18.11 Metal Injection Molding（MIM）or Powder Injection Molding（PIM）

18.12 Secondary Operations

18.13 Properties of P/M Products

18.14 Design of Powder Metallurgy Parts

18.15 Powder Metallurgy Products

18.16 Advantages and Disadvantages of Powder Metallurgy

18.17 Process Summary

Case Study Impeller for an Automobile Water Pump

Chapter 19 Electronic Electrochemical Chemical and Thermal Machining Processes

19.1 Introduction

19.2 Chemical Machining Processes

19.3 Electrochemical Machining Processes

19.4 Electrical Discharge Machining

Case Study Fire Extinguisher Pressure Gage

Chapter 20 Fundamentals of Machining/Orthogonal Machining

20.1 Introduction

20.2 Fundamentals

20.3 Energy and Power in Machining

20.4 Orthogonal Machining（Two Forces）

20.5 Merchant’s Model

20.6 Mechanics of Machining（Statics）

20.7 Shear Strain γ and Shear Front Angle？

20.8 Mechanics of Machining（Dynamics）

20.9 Summary

Case Study Orthogonal Plate Machining Experiment at Auburn University

Chapter 21 Cutting Tools for Machining

21.1 Introduction

21.2 Cutting-Tool Materials

21.3 Tool Geometry

21.4 Tool Coating Processes

21.5 Tool Failure and Tool Life

21.6 Flank Wear

21.7 Economics of Machining

21.8 Cutting Fluids

Case Study Comparing Tool Materials Based on Tool Life

Chapter 22 Turning and Boring Processes

22.1 Introduction

22.2 Fundamentals of Turning，Boring，and Facing Turning

22.3 Lathe Design and Terminology

22.4 Cutting Tools for Lathes

22.5 Workholding in Lathes

Case Study Estimating the Machining Time for Turning

Chapter 23 Drilling and Related Hole-Making Processes

23.1 Introduction

23.2 Fundamentals of the Drilling Process

23.3 Types of Drills

23.4 Tool Holders for Drills

23.5 Workholding for Drilling

23.6 Machine Tools for Drilling

23.7 Cutting Fluids for Drilling

23.8 Counterboring，Countersinking，and Spot Facing

23.9 Reaming

Case Study Bolt-down Leg on a Casting

Chapter 24 Milling

24.1 Introduction

24.2 Fundamentals of Milling Processes

24.3 Milling Tools and Cutters

24.4 Machines for Milling

Case Study HSS versus Tungsten Carbide Milling

Chapter 25 Workholding Devices for Machine Tools

25.1 Introduction

25.2 Conventional Fixture Design

25.3 Design Steps

25.4 Clamping Considerations

25.5 Chip Disposal

25.6 Unloading and Loading Time

25.7 Example of Jig Design

25.8 Types of Jigs

25.9 Conventional Fixtures

25.10 Modular Fixturing

25.11 Setup and Changeover

25.12 Clamps

25.13 Other Workholding Devices

25.14 Economic Justification of Jigs and Fixtures

Case Study Fixture versus No Fixture in Milling

Chapter 26 Numerical Control（NC）and the A（4）Level of Automation

26.1 Introduction

26.2 Basic Principles of Numerical Control

26.3 Machining Center Features and Trends

26.4 Ultra-High-Speed Machining Centers（UHSMCs）

26.5 Summary

Case Study Process Planning for the MfE

Chapter 27 Other Machining Processes

27.1 Introduction

27.2 Introduction to Shaping and Planing

27.3 Introduction to Broaching

27.4 Fundamentals of Broaching

27.5 Broaching Machines

27.6 Introduction to Sawing

27.7 Introduction to Filing

Case Study Cost Estimating—Planing vs.Milling

Chapter 28 Abrasive Machining Processes

28.1 Introduction

28.2 Abrasives

28.3 Grinding Wheel Structure and Grade

28.4 Grinding Wheel Identification

28.5 Grinding Machines

28.6 Honing

28.7 Superfinishing

28.8 Free Abrasives

Case Study Overhead Crane Installation

Chapter 29 Thread and Gear Manufacturing

29.1 Introduction

29.2 Thread Making

29.3 Internal Thread Cutting-Tapping

29.4 Thread Milling

29.5 Thread Grinding

29.6 Thread Rolling

29.7 Gear Making

29.8 Gear Types

29.9 Gear Manufacturing

29.10 Machining of Gears

29.11 Gear Finishing

29.12 Gear Inspection

Case Study Bevel Gear for a Riding Lawn Mower

Chapter 30 Fundamentals of Joining

30.1 Introduction to Consolidation Processes

30.2 Classification of Welding and Thermal Cutting Processes

30.3 Some Common Concerns

30.4 Types of Fusion Welds and Types of Joints

30.5 Design Considerations

30.6 Heat Effects

30.7 Weldability or Joinability

30.8 Summary

Chapter 31 Gas Flame and Arc Processes

31.1 Oxyfuel-Gas Welding

31.2 Oxygen Torch Cutting

31.3 Flame Straightening

31.4 Arc Welding

31.5 Consumable-Electrode Arc Welding

31.6 Nonconsumable-Electrode Arc Welding

31.7 Welding Equipment

31.8 Arc Cutting

31.9 Metallurgical and Heat Effects in Thermal Cutting

Case Study Bicycle Frame Construction and Repair

Chapter 32 Resistance and Solid-State Welding Processes

32.1 Introduction

32.2 Theory of Resistance Welding

32.3 Resistance Welding Processes

32.4 Advantages and Limitations of Resistance Welding

32.5 Solid-State Welding Processes

Case Study Field Repair to a Power Transformer

Chapter 33 Other Welding Processes，Brazing and Soldering

33.1 Introduction

33.2 Other Welding and Cutting Processes

33.3 Surface Modification by Welding-Related Processes

33.4 Brazing

33.5 Soldering

Chapter 34 Adhesive Bonding，Mechanical Fastening，and Joining of Nonmetals

34.1 Adhesive Bonding

34.2 Mechanical Fastening

34.3 Joining of Plastics

34.4 Joining of Ceramics and Glass

34.5 Joining of Composites

Case Study Golf Club Heads with Insert

Chapter 35 Surface Engineering

35.1 Introduction

35.2 Mechanical Cleaning and Finishing Blast Cleaning

35.3 Chemical Cleaning

35.4 Coatings

35.5 Vaporized Metal Coatings

35.6 Clad Materials

35.7 Textured Surfaces

35.8 Coil-Coated Sheets

35.9 Edge Finishing and Burrs

35.10 Surface Integrity

Case Study Dana Lynn’s Fatigue Lesson

Chapter 36 Quality Engineering

36.1 Introduction

36.2 Determining Process Capability

36.3 Inspection to Control Quality

36.4 Process Capability Determination from Control Chart Data

36.5 Determining Causes for Problems in Quality

36.6 Summary

Case Study Boring QC Chart Blunders

Index